CCS module capable of increasing welding speed of nickel sheet on wire harness

Abstract

The utility model discloses a CCS module capable of accelerating the welding speed of a nickel sheet on a wire harness, which comprises an aluminum bar, a plastic uptake shell for positioning the aluminum bar and the wire harness clamped on the plastic uptake shell, the wire harness is provided with the nickel sheet, the nickel sheet is fixed on the aluminum bar in a welding manner, and the nickel sheet is fixed on the aluminum bar in a welding manner. A first accommodating groove for accommodating the aluminum bar and a second accommodating groove for accommodating the wire harness are formed in the plastic uptake shell, limiting bulges for limiting the aluminum bar are arranged on the periphery of the side wall of the first accommodating groove, and the limiting bulges are in interference fit with the side edge of the aluminum bar; and an avoiding gap for the nickel sheet on the wire harness to extend into the aluminum bar is arranged between the first accommodating groove and the second accommodating groove. The positioning method of the aluminum row and the blister shell is simple and convenient, the aluminum row can be quickly positioned on the blister shell, the assembling efficiency of the aluminum row and the blister shell is improved, and the welding speed of nickel sheets is increased.

Description

[Technical Field]

[0001] This utility model belongs to the field of battery technology, and in particular relates to a CCS module that can accelerate the welding speed of nickel sheets on wire harnesses. [Background Technology]

[0002] As the core component of the safety monitoring center for power batteries in new energy vehicles, the CCS plays a crucial role in the safety performance of these vehicles. CCS, also known as the integrated busbar or wiring harness board, mainly consists of wiring harnesses, a vacuum-formed housing, and aluminum busbars. The assembly sequence is as follows: first, the aluminum busbars are assembled onto the vacuum-formed housing; then, the nickel strips on the wiring harness are soldered onto the aluminum busbars to obtain the CCS. When positioning the aluminum busbars onto the vacuum-formed housing, a conventional design involves setting several positioning posts on the housing, as disclosed in Chinese Patent Publication No. CN215220934U. In a type of blister pack, CCS module, battery module, and automobile, the aluminum busbar fixing part is provided with several first grooves, and the aluminum busbar is placed in the first grooves. Several cylinders are provided on the first grooves, and the relative positions between the cylinders match the relative positions between the circular holes of the aluminum busbar. The cylinders pass through the circular holes of the aluminum busbar and are fixed by heat riveting. Several positioning holes are provided on the aluminum busbar. The increase in holes on the aluminum busbar will reduce the current carrying capacity of the aluminum busbar on the one hand, and on the other hand, the assembly speed of the aluminum busbar and the blister pack will be reduced by heat-melting multiple positioning pins to position the aluminum busbar, thereby reducing the welding speed of the nickel strip on the line.

[0003] In the prior art, a CCS module and battery module disclosed in Chinese Patent Publication No. CN219591605U restricts the movement of the busbar in the left and right directions by a first limiting block and a second limiting block. The busbar can be pressed down on a protrusion, causing the spring to elastically deform. The busbar and the plastic plate can move relative to each other within the elastic deformation range of the spring, forming an interference fit and limiting the front and rear directions of the busbar. A snap-fit ​​component limits the vertical direction of the aluminum busbar. Therefore, the above solution can quickly position the busbar onto the plastic plate and can limit the front and rear, left and right movements of the busbar. The right and up / down direction limits ensure the accuracy of nickel sheet welding. Although the above solution can achieve positioning between the busbar and the plastic plate, the following problems still exist: the spring is elastically floating. When welding nickel sheets onto the aluminum busbar, there will be a pressing force on the aluminum busbar. The floating of the spring will affect the position of the nickel sheet welding, thus reducing the consistency of the nickel sheet welding position. Moreover, the positioning structure of the positioning aluminum busbar set on the plastic plate includes a first limiting block, a second limiting block, a spring, and a buckle assembly. The positioning structure is multiple and complex, which will reduce the positioning speed of the busbar, thereby reducing the welding speed of the nickel sheet.

[0004] Therefore, it is necessary to provide a CCS module that can accelerate the welding speed of nickel sheets on wire harnesses to solve the above-mentioned technical problems. [Utility Model Content]

[0005] The main purpose of this utility model is to provide a CCS module that can accelerate the welding speed of nickel sheets on wire harnesses. The positioning method of aluminum busbar and blister shell is simple and convenient, which can realize the rapid positioning of aluminum busbar on blister shell, improve the assembly efficiency of aluminum busbar and blister shell and increase the welding speed of nickel sheets.

[0006] This utility model achieves the above-mentioned objective through the following technical solution: a CCS module that can accelerate the welding speed of nickel sheets on a wire harness, comprising an aluminum busbar, a blister shell for positioning the aluminum busbar, and a wire harness clipped onto the blister shell. Nickel sheets are disposed on the wire harness and are fixed to the aluminum busbar by welding. The blister shell is provided with a first receiving groove for placing the aluminum busbar and a second receiving groove for placing the wire harness. Limiting protrusions for limiting the aluminum busbar are provided around the sidewalls of the first receiving groove, and the limiting protrusions are interference-fitted with the side of the aluminum busbar. An avoidance notch is provided between the first receiving groove and the second receiving groove to allow the nickel sheets on the wire harness to extend into the aluminum busbar.

[0007] Furthermore, the limiting protrusions are arranged in pairs, with several pairs of limiting protrusions arranged opposite each other on the two opposite long sides of the first receiving groove, and at least one pair of limiting protrusions arranged opposite each other on the two opposite short sides.

[0008] Furthermore, the limiting protrusion includes an inclined guide surface at the upper end and a vertical positioning surface at the lower end. When the aluminum busbar is fully positioned in the first receiving groove, the side of the aluminum busbar and the positioning surface are in an interference fit.

[0009] Furthermore, several aluminum busbars are arranged at intervals along the length direction of the blister shell to form an aluminum busbar group, and several first receiving grooves are correspondingly provided on the blister shell; the wire harness is disposed on the front or rear side of the aluminum busbar group, the wire harness extends along the length direction of the blister shell, and several nickel sheets extend from different positions of the wire harness toward the width direction of the blister shell, and the nickel sheets at different positions are welded to the corresponding aluminum busbars.

[0010] Furthermore, the blister shell is provided with a first blocking part between the aluminum busbar assembly and the wire harness to separate the aluminum busbar assembly and the wire harness, the clearance notch is provided on the first blocking part, and the clearance notch is provided with a blocking block to separate the clearance notch.

[0011] Furthermore, two wire harnesses are provided between two adjacent aluminum busbar groups, and two second receiving slots are provided correspondingly between two adjacent first receiving slots. A plurality of second blocking portions are provided between the two second receiving slots to separate the two wire harnesses.

[0012] Furthermore, a pressure relief hole is provided in the middle of the second blocking part.

[0013] Furthermore, the first receiving groove is configured to conform to the shape of the aluminum busbar, and the bottom of the first receiving groove is provided with a first clearance hole to avoid the nickel sheet and a second clearance hole to avoid the battery cell electrode post.

[0014] Furthermore, the second receiving groove is provided with several pairs of binding holes for the binding wire to pass through, so as to achieve the binding wire to constrain and fix the wire bundle.

[0015] Furthermore, the blister shell is elastic and is a one-piece structure formed by the blister forming process.

[0016] Compared with the prior art, the beneficial effects of this utility model of a CCS module that can accelerate the welding speed of nickel sheets on wire harnesses are as follows:

[0017] (1) The side walls of the first receiving groove are provided with limiting protrusions to limit the aluminum strip. The limiting protrusions are interference fit with the side of the aluminum strip. When the aluminum strip is positioned in the first receiving groove, the front and rear sides of the aluminum strip are restricted on the limiting protrusions on the front and rear sides of the first receiving groove, and the left and right sides of the aluminum strip are restricted on the limiting protrusions on the front and rear sides of the first receiving groove. The positioning between the aluminum strip and the limiting protrusions is achieved by interference fit. Therefore, after the aluminum strip is positioned on the blister shell, it can restrict the movement of the aluminum strip in the front, back, left, right and up directions, and realize the positioning restriction of the aluminum strip in three dimensions. The positioning method of the aluminum strip and the blister shell is simple and convenient, and can realize the rapid positioning of the aluminum strip on the blister shell, improve the assembly efficiency of the aluminum strip and the blister shell, and thus improve the production efficiency.

[0018] (2) The limiting protrusions are set in pairs, which can not only ensure the accurate positioning of the limiting protrusions and the aluminum strip, but also ensure the local strength of the blister shell and avoid local deformation of the blister shell.

[0019] (3) The first blocking part can separate the aluminum busbar and the wire harness. The clearance notch on the first blocking part can facilitate the nickel sheet on the wire harness to extend into the aluminum busbar. The blocking block between the clearance notches can prevent the two nickel sheets from contacting and interfering with each other. The clearance notch can also facilitate the insertion of manual fingers to install or remove the aluminum busbar from the clearance notch, thereby improving production efficiency. [Attached Image Description]

[0020] Figure 1 This is a three-dimensional structural diagram of a CCS module that can accelerate the welding speed of nickel sheets on wire harnesses according to an embodiment of the present invention;

[0021] Figure 2 This is a three-dimensional structural diagram of the blister shell according to an embodiment of the present utility model;

[0022] Figure 3 This is an embodiment of the present utility model. Figure 2 Enlarged structural diagram of section A in the middle;

[0023] Figure 4 This is an embodiment of the present utility model. Figure 3 Enlarged structural diagram of section B in the middle;

[0024] The numbers in the diagram represent:

[0025] 100 - A CCS module that can accelerate the soldering speed of nickel sheets on wire harnesses;

[0026] 1-Aluminum busbar;

[0027] 2-Blister shell, 21-First receiving groove, 211-First clearance hole, 212-Second clearance hole, 22-Second receiving groove, 221-Tied wire hole, 23-Limiting protrusion, 231-Guide surface, 232-Positioning surface, 24-Clearing notch, 25-First blocking part, 26-Blocking block, 27-Second blocking part, 271-Pressure relief hole;

[0028] 3-Wire harness; 4-Nickel sheet.

Detailed Implementation Methods

[0029] Please refer to Figures 1-4 This embodiment is a CCS module 100 that can accelerate the welding speed of nickel sheets on wire harnesses. The CCS module 100 includes an aluminum busbar assembly, a blister shell 2 for positioning the aluminum busbar assembly, and a wire harness 3 that is clipped onto the blister shell 2. The aluminum busbar assembly includes a plurality of aluminum busbars 1 spaced apart. A plurality of nickel sheets 4 are provided on the wire harness 3. The nickel sheets 4 are fixed to the aluminum busbars 1 by welding. The blister shell 2 is provided with a plurality of first receiving grooves 21 for placing the aluminum busbars 1 and a second receiving groove 22 for placing the wire harness 3. The side walls of the first receiving groove 21 are provided with limiting protrusions 23 for limiting the aluminum busbars 1. The limiting protrusions 23 are interference-fitted with the side of the aluminum busbars 1. A clearance notch 24 is provided between the first receiving groove 21 and the second receiving groove 22 for the nickel sheets 4 on the wire harness 3 to extend into the aluminum busbars 1.

[0030] Limiting protrusions 23 are disposed on the four sides of the first receiving groove 21. The limiting protrusions 23 are arranged in pairs, that is, every two limiting protrusions 23 form a group. In this embodiment, two pairs of limiting protrusions 23 are disposed on each of the two opposite long sides of the first receiving groove 21, and one pair of limiting protrusions 23 are disposed on each of the two opposite short sides. In other embodiments, the number of limiting protrusions can be set according to the actual length and width of the aluminum busbar 1, and the number of limiting protrusions 23 can be appropriately increased or decreased, which is not limited here. The limiting protrusions 23 include an inclined guide surface 231 at the upper end and a vertical positioning surface 232 at the lower end. The guide surface 231 is set at an angle to the vertical surface. The guide surface 231 facilitates the smooth entry of the aluminum busbar 1 into the first receiving groove 21. When the aluminum busbar 1 is completely positioned in the first receiving groove 21, the upper surface of the aluminum busbar 1 is lower than the height of the positioning surface 232, and the side of the aluminum busbar 1 is interference-fitted with the positioning surface 232, which can restrict the movement of the aluminum busbar 1. Since the aluminum strip 1 and the positioning surface 232 are interference fit, the limiting protrusions 23 are set in pairs, which can not only ensure the accurate positioning of the limiting protrusions 23 and the aluminum strip 1, but also ensure the local strength of the blister shell 1 and avoid local deformation of the blister shell 2.

[0031] When manually placing the aluminum strip 1 into the first receiving groove 21, hold one side of the aluminum strip 1 and insert your hand through the clearance notch 24 to place the aluminum strip 1 into the first receiving groove 21. The other side of the aluminum strip 1 should enter from the guide surface 231 and abut against the limiting protrusion 23 opposite to the clearance notch 24. Both ends of the aluminum strip 1 should enter from the guide surface 231 and abut against the limiting protrusions 23 on the left and right sides. Then, retract your fingers to keep the aluminum strip 1 horizontal. Next, press the aluminum strip 1 downwards into the first receiving groove 21 from above, so that the bottom surface of the aluminum strip 1 contacts the bottom of the first receiving groove 21, completing the positioning of the aluminum strip 1 on the vacuum forming 2. The side of the aluminum strip 1 should be aligned with the positioning surface 232. All are interference fits. At this time, the front and rear sides of the aluminum busbar 1 are restricted on the limiting protrusions 23 on the front and rear sides of the first receiving groove 21, and the left and right sides of the aluminum busbar 1 are restricted on the limiting protrusions 23 on the front and rear sides of the first receiving groove 21. The positioning between the aluminum busbar 1 and the limiting protrusions 23 is achieved by interference fit. Therefore, after the aluminum busbar 1 is positioned on the blister shell 2, it can restrict the movement of the aluminum busbar 1 in the front-back, left-right and up-down directions, and realize the positioning restriction of the aluminum busbar 1 in three-dimensional direction. The positioning method of the aluminum busbar 1 and the blister shell 2 is simple and convenient, which can realize the rapid positioning of the aluminum busbar 1 on the blister shell 2, improve the assembly efficiency of the aluminum busbar 1 and the blister shell 2, and thus improve the welding speed of the nickel sheet.

[0032] Several aluminum bars 1 are arranged at intervals along the length of the blister shell 2 to form an aluminum bar group. Several first receiving slots 21 are correspondingly provided on the blister shell 2. Each row of several first receiving slots 21 forms a group, and each group of first receiving slots 21 corresponds one-to-one with each aluminum bar group. The wire harness 3 is located on the front or rear side of the aluminum busbar assembly. The wire harness 3 extends along the length of the blister shell 2. At different positions along the length of the wire harness 3, several nickel sheets 4 extend into the width of the blister shell 2. The nickel sheets 4 at different positions are welded to the corresponding aluminum busbars 1. To avoid contact interference between the wire harness 3 and the aluminum busbars 1, the blister shell 2 has a first blocking part 25 between the aluminum busbar assembly and the wire harness 3 to separate them. A clearance notch 24 is provided on the first blocking part 25. Since two nickel sheets 4 need to be welded to each aluminum busbar, two clearance notches 24 are provided on the first blocking part 25. A blocking block 26 is provided between the two clearance notches 24 to separate them. When the two nickel sheets 4 are inserted into the two clearance notches 24 respectively, the blocking block 26 can prevent the two nickel sheets 4 from contacting and interfering with each other. The clearance notch 24 also facilitates the insertion of manual fingers to install or remove the aluminum busbars 1 from the clearance notch 24, thereby improving production efficiency.

[0033] To achieve a compact layout, two wire harnesses 3 are positioned between adjacent aluminum busbar groups, and two second receiving slots 22 are correspondingly positioned between adjacent first receiving slots 21. Nickel tabs 4 on the front wire harness 3 extend forward into the front aluminum busbar 1, and nickel tabs 4 on the rear wire harness 3 extend backward into the rear aluminum busbar 1. Several second blocking portions 27, separating the two wire harnesses 3, are positioned between the two second receiving slots 22. These second blocking portions 27 are arranged along the length of the blister shell 2 to prevent the front and rear wire harnesses 3 from contacting and interfering with each other. A pressure relief hole 271 is located in the middle of each second blocking portion 27. The pressure relief hole 271 is designed to improve safety. When an abnormal situation occurs inside the battery, such as thermal runaway of the cell causing a rapid increase in internal pressure, the pressure relief hole can release pressure in time, preventing the battery casing from cracking or exploding. This protects the surrounding environment and personnel, contributing to improved overall battery safety and reliability.

[0034] The first receiving groove 21 is set in the same shape as the aluminum busbar 1. The bottom of the first receiving groove 21 is provided with a first clearance hole 211 to avoid the nickel sheet 4 and a second clearance hole 212 to avoid the battery cell terminal (not shown in the figure), which facilitates the welding of other structures at the bottom of the aluminum busbar 1.

[0035] The second receiving groove 22 is provided with several pairs of binding holes 221 for binding wires (not shown in the figure) to pass through. When the wire harness 4 is placed in the second receiving groove 22, each pair of binding holes 221 is located on the front and rear sides of the wire harness 3 respectively. The binding wire enters from the binding hole 221 on one side of the wire harness 4 and extends from the binding hole 221 on the other side of the wire harness 4, and is tied to the wire harness 4 to constrain and fix the wire harness 4, preventing the wire harness 4 from falling off during use and causing abnormalities, thereby improving the safety of this CCS module.

[0036] The blister shell 2 is elastic and is a one-piece structure formed by blister forming process. The limiting protrusion 23, the first blocking part 25, the blocking block 26, the second blocking part 27, the first receiving groove 21, the second receiving groove 22, and the avoidance notch 24 on the blister shell 2 are all formed by blister forming at the same time, which can improve the stability of the CCS module structure.

[0037] The positioning structure of the nickel sheet 4 and the aluminum busbar 1 can quickly position the nickel sheet 4 onto the aluminum busbar 1, thereby improving the welding efficiency of the nickel sheet 4. Its specific structure has been described in detail in the conformal positioning structure that can improve the welding efficiency of nickel sheets disclosed in Chinese Patent Publication No. CN221952620U, and will not be repeated here.

[0038] The assembly process of the CCS module 100, which can accelerate the welding speed of nickel sheets on the wire harness, is as follows: A person holds one side of the aluminum busbar 1 and inserts their hand through the clearance notch 24 into the first receiving groove 21. The other side of the aluminum busbar 1 enters from the guide surface 231 and abuts against the limiting protrusion 23 opposite to the clearance notch 24. Both ends of the aluminum busbar 1 enter from the guide surface 231 and abut against the limiting protrusions 23 on the left and right sides. Then, the fingers are withdrawn to keep the aluminum busbar 1 horizontal. Then, the aluminum busbar 1 is pressed downwards into the first receiving groove 21 from above, so that the bottom surface of the aluminum busbar 1 contacts the bottom of the first receiving groove 21, completing the positioning of the aluminum busbar 1 on the vacuum forming 2. The sides of the aluminum busbar 1 and the positioning surface 232 are both interference fits. At this time, the front and rear sides of the aluminum busbar 1 are restricted by the front and rear of the first receiving groove 21. The aluminum busbar 1 is restricted on the limiting protrusions 23 on both sides and the left and right sides of the aluminum busbar 1 is restricted on the limiting protrusions 23 on the front and rear sides of the first receiving groove 21. The aluminum busbar 1 and the limiting protrusions 23 are positioned by interference fit. When the aluminum busbar 1 is positioned on the blister shell 2 in the above manner, the wire harness 3 is placed in the second receiving groove 22. Each pair of binding holes 221 are located on the front and rear sides of the wire harness 3. The binding wire passes through the binding hole 221 on one side of the wire harness 4 and extends out from the binding hole 221 on the other side of the wire harness 4, and is tied to the wire harness 4 to constrain and fix the wire harness 4. At the same time, correspondingly, several nickel plates 4 are located above the positioning structure of the aluminum busbar 1. The nickel plates 4 are pressed down to position the nickel plates 4 on the positioning structure of the aluminum busbar 1 for welding operation. After welding is completed, it is moved to the next station for subsequent operation.

[0039] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A CCS module that can accelerate the welding speed of nickel sheets on wire harnesses, characterized in that: It includes an aluminum busbar, a blister pack for positioning the aluminum busbar, and a wire harness attached to the blister pack. The wire harness has a nickel sheet attached to it and is fixed to the aluminum busbar by welding. The blister pack has a first receiving groove for placing the aluminum busbar and a second receiving groove for placing the wire harness. The sidewalls of the first receiving groove are provided with limiting protrusions to limit the movement of the aluminum busbar. The limiting protrusions are interference-fitted with the sidewalls of the aluminum busbar. There is a clearance notch between the first receiving groove and the second receiving groove to allow the nickel sheet on the wire harness to extend into the aluminum busbar.

2. The CCS module as described in claim 1, which can accelerate the welding speed of nickel sheets on wire harnesses, is characterized in that: The limiting protrusions are arranged in pairs. Several pairs of the limiting protrusions are arranged opposite each other on the two opposite long sides of the first receiving groove, and at least one pair of the limiting protrusions are arranged opposite each other on the two opposite short sides.

3. The CCS module as described in claim 1, which can accelerate the welding speed of nickel sheets on wire harnesses, is characterized in that: The limiting protrusion includes an inclined guide surface at the upper end and a vertical positioning surface at the lower end. When the aluminum busbar is fully positioned in the first receiving groove, the side of the aluminum busbar and the positioning surface are in an interference fit.

4. The CCS module as described in claim 1, which can accelerate the welding speed of nickel sheets on wire harnesses, is characterized in that: A plurality of aluminum busbars are arranged at intervals along the length of the blister shell to form an aluminum busbar group, and a plurality of first receiving grooves are correspondingly provided on the blister shell; the wire harness is disposed on the front or rear side of the aluminum busbar group, the wire harness extends along the length of the blister shell, and a plurality of nickel sheets extend from different positions of the wire harness toward the width of the blister shell, and the nickel sheets at different positions are welded to the corresponding aluminum busbars.

5. A CCS module as described in claim 4, characterized in that: The blister shell has a first blocking part between the aluminum busbar assembly and the wire harness to separate the aluminum busbar assembly and the wire harness. The clearance notch is provided on the first blocking part, and the clearance notch is separated by blocking blocks.

6. A CCS module as described in claim 4, characterized in that: Two wire harnesses are provided between two adjacent aluminum busbar groups, and two second receiving slots are provided correspondingly between two adjacent first receiving slots. A plurality of second blocking parts are provided between the two second receiving slots to separate the two wire harnesses.

7. A CCS module as described in claim 6, characterized in that: A pressure relief hole is provided in the middle of the second blocking part.

8. A CCS module as described in claim 1, characterized in that: The first receiving groove is configured to conform to the shape of the aluminum busbar, and the bottom of the first receiving groove is provided with a first clearance hole to avoid the nickel sheet and a second clearance hole to avoid the battery cell electrode post.

9. A CCS module as described in claim 1, characterized in that: The second receiving groove is provided with several pairs of binding holes for the binding wire to pass through, so as to achieve the binding wire to constrain and fix the wire bundle.

10. A CCS module as described in claim 1, characterized in that: The blister shell is elastic and is a one-piece structure formed by blister molding.

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